level and pressure instrumentation for renewable energies

Anwendungsbeispiele und ProdukteApplication examples and products

Level and pressure instrumentation for renewable energies

Dam of the hydroelectric power plant

Flow measurement

Water inlet at the reservoir

Level measurement and point level detection

Turbine building hydro-electric power plant


Reservoir at pumped storage power plants

Level measurement

Expansion tank in a thermal solar plant

Level and pressure measurement

Gearbox oil tank in a wind turbine

Point level detection

Wood pellet storage silo


Compact slurry tanks in biogas plants

Level measurement

Slurry tanks in biogas plants

Pressure measurement and point level detection

Raw material silo in the ethanol plant


Fermentation in the ethanol plant

Pressure and level measure-ment, point level detection

Storage tank in the ethanol plant


This brochure presents examples of applied level and pressure measurement technology.

Here, you’ll learn which sensors fit which measuring tasks.

All applications can be found at

www.vega.com/energy

Measurement technology for renewable energies

Continuous level measurement

Instrument type Measuring range

Process fitting

Process temperature

Process pressure

VEGAFLEX 81

TDR sensor for continuous level and interface measurement of liquids

up to 75 m Thread from G¾, ¾ NPT, flanges from DN 25, 1"

-60 … +200 °C -1 … +40 bar (-100 … +4000 kPa)

VEGAPULS WL 61

Radar sensor for continuous level measurement of water and waste water

up to 15 m Thread G1½, mounting strap, compression flanges from DN 80, 3"

-40 … +80 °C -1 … +2 bar (-100 … +200 kPa)

VEGAPULS 62

Radar sensor for continuous level measurement of liquids

up to 35 m Thread from G1½, 1½ NPT, flanges from DN 50, 2"

-196 … +450 °C -1 … +160 bar (-100 … +16000 kPa)

VEGAPULS 69

Radar sensor for continuous level measurement of bulk solids

up to 120 m Mounting strap, compression flange from DN 80, 3", flang-es from DN 80, 3", adapter flanges from DN 100, 4"

-40 … +200 °C -1 … +3 bar (-100 … +300 kPa)

Point level detection

Instrument type Measuring range

Process fitting

Process temperature

Process pressure

VEGACAP 64

Capacitive rod electrode for level detection of adhesive products


-50 … +200 °C -1 … +64 bar (-100 … +6400 kPa)

VEGAMIP 61

Microwave barrier for level detection in bulk solids and liquids

up to 100 m Thread from G1½, 1½ NPT, flanges, clamp, mounting strap

-40 … +80 °C +450 °C with mounting adapter

-1 … +4 bar (-100 … +400 kPa)

VEGASWING 61

Vibrating level switch for liquids


-50 … +250 °C -1 … +64 bar (-100 … +6400 kPa)

VEGASWING 63

Vibrating level switch with tube extension for liquids


-50 … +250 °C -1 … +64 bar (-100 … +6400 kPa)

VEGAVIB 62

Vibrating level switch with suspension cable for granular bulk solids

Bulk solids from 20 g/l

Thread from G1, 1 NPT, flanges from DN 32, 1½"

-40 … +150 °C -1 … +6 bar (-100 … +600 kPa)

VEGAVIB 63

Vibrating level switch with tube extension for granular bulk solids

Bulk solids from 20 g/l

Thread from G1, 1 NPT, flanges from DN 32, 1½"

-50 … +250 °C -1 … +16 bar (-100 … +1600 kPa)

Pressure measurement

Instrument type Deviation Process fitting

Process temperature

Measuring range

VEGABAR 81

Pressure transmitter with chemical seal

0.2 % Thread from G½, ½ NPT, flanges from DN 25, 1"

-90 … +400 °C -1 … +1000 bar (-100 … +100000 kPa)

VEGABAR 82

Pressure transmitter with ceramic measuring cell

0.2 % 0.1 % 0.05 %

Thread G½, ½ NPT, flanges from DN 15, 1½"

-40 … +150 °C -1 … +100 bar (-100 … +10000 kPa)

VEGAWELL 52

Pressure transmitter with ceramic measuring cell

0.1 % 0.2 %

Straining clamp, thread, suspension cable, threaded fitting of 316L, PVDF, Duplex, Titanium

-20 … +80 °C 0 … +60 bar (0 … +6000 kPa)

All sensors at a glance

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Proven and precise instrumentation

VEGA is the experienced supplier of level and pressure sensors

for renewable energy applications.

VEGA sensors deliver precise measurement data as the basis

for automatic control of processes in your facility. All sensors are

based on state-of-the-art technology and optimised and certified

for use in the renewable energy sector.

Cost e�ective technology

Quality pays o¤: the robust sensors reduce operating and

maintenance costs as well as downtime.

Reliable measurement

Instrumentation from VEGA is reliable and accurate under all

measuring conditions. The wide range of available sensors covers

virtually all process conditions and operating environments found

in today’s industries.

Fast delivery

Whether initial delivery or repair: VEGA instruments arrive at your

facility within a few days. This significantly reduces stocking costs

and keeps your plant running continuously.

Renewable energies

Instrument platform plics®

The plics® idea is simple: Each instrument is assembled from

prefabricated components once the order is received. This modular

design allows full flexibility when selecting the required sensor

features. You receive your customised, user-friendly instrument

within an amazingly short time. The best part: these instruments are

more cost-e¤ective and advantageous in every way – throughout

their entire life cycle.

Display and adjustment

The display and adjustment module PLICSCOM is used for

measured value indication, adjustment and diagnosis directly

on the sensor. Its simple menu structure enables quick setup.

Status messages are displayed in plain text. The optional

Bluetooth feature allows wireless operation.

Connection

The VEGACONNECT connects your instrument to a PC via the

USB interface. PLICSCOM with Bluetooth enables data transfer

with wireless technology. The instruments are configured with

the tried and trusted adjustment software PACTware and the

appropriate DTM or with an app on a smartphone or tablet PC.

For EDD-based systems we also o¤er graphics-driven EDDs.

Asset management and maintenance

The integrated self-monitoring function of plics® instruments

permanently informs the user on the status of the instruments.

Status messages allow proactive and cost-e¤ective maintenance.

All diagnostic data can be called up easily and quickly in plain

text via the built-in memory functions.

plics® − easy is better

3

Flow measurement at the dam

The seepage water in the dam of the hydroelectric plant is collected in pipes or

channels. The quantity of seepage water provides information on the condition

of the dam (another indicator of the condition of the dam is the clouding of the

seepage water which is also assessed). The quantity of water flowing in an open

channel is measured via water head height as it passes through a ‘V’ notch,

flume or weir structure, which is then calculated into flow rate.

VEGAPULS WL 61

Non-contact flow measurement with radar at the dam

of the hydroelectric power plant

▪ Non-contact, high accuracy flow measurement

▪ Una¤ected by environmental influences

▪ Simple mounting and setup reduces installation costs

Dam of the hydroelectric power plant

ReliableReliable flow measurement allows reliable detection of leaks in the dam

Cost e�ectiveSensor with high protection rating for long service life, even under extremely humid conditions

User friendlyEasy setup via external display and adjustment unit

4

Level measurement and point level detection of stones and sand in the water basin

If the natural flow of water into a reservoir is not su±cient for optimal energy

production, additional water is fed into the reservoir via ducts or tunnels from

water catchments that can be up to several kilometres distant. Coarse debris

is held back by massive grids at the main water inlet. Smaller stones, grit and

sand can accumulate in the transfer basin in front of the tunnel. Constant

monitoring of the level of stones and sand in the basin ensures that no debris

gets into the tunnel system.

VEGAVIB 62

Point level detection with vibrating level switch for on-demand

cleaning of the basin of stones and sand

▪ Reliable level measurement, una¤ected

by debris

▪ Robust design ensures dependable function

▪ Maintenance-free operation reduces

maintenance costs

VEGAWELL 52

Hydrostatic level measurement for determining the level

in the water basin

▪ High availability thanks to non-wearing ceramic measuring cell

▪ Simple mounting and setup reduces installation costs

▪ High resistance to abrasion from foreign bodies

Water inlet at the reservoir

Reliable

Reliable level switch protects the

tunnel system from rocks and sand

Cost e�ective

Flushing only on demand

User friendly

Automatic operation

5

Level and point level detection in the seepage water shaft

At the lowest point of the hydroelectric power station, cooling water from

the generators and any leakage water from the Kaplan or Francis turbines

is collected in a seepage water shaft, pit or sump. To prevent a flooding

of the shaft and thus of the turbine building, with disastrous results for

equipment, the sensors are often installed redundantly. As additional

protection, the maximum water level is monitored with a point level switch.

VEGAWELL 52

Hydrostatic level measurement for monitoring the water level

in the seepage shaft

▪ High-resistance ceramic measuring cell ensures

high availability

▪ Excellent long-term stability reduces the need

for maintenance

▪ Simple mounting and setup reduces installation

costs

VEGASWING 63

Level detection with vibrating level switch as overfill protection

in the seepage water shaft

▪ High switching reliability through continuous self-monitoring

▪ Low maintenance costs thanks to wear-free measuring

principle

▪ Simple setup and commissioning through adjustment-free

sensor design

Reliable

Protection against flooding of the

turbine building with high reliability water

level detection of the seepage shaft

Cost e�ective

Optimal operation and monitoring

of the pumps

User friendly

Easy installation, even in tight spaces

Turbine building hydroelectric power plant

6

Reservoir level measurement

Pumped storage power plants store a large amount of energy and feed it into

the grid very quickly when necessary. One important parameter is the height

of the water level in the reservoir. It allows calculations to be made about the

amount of energy available and the existing storage volume in pump operation

mode. High reliability is required from the measurement technology deployed,

because the sensors are often mounted at very remote locations.

VEGAWELL 52

Hydrostatic level measurement for monitoring the water level

in the reservoir

▪ Robust submersible pressure sensor design ensures high

availability

▪ Wear-free ceramic measuring cell minimizes maintenance costs

▪ Simple mounting and setup

Reservoir at pumped storage power plants

Reliable

Ensures reliable e±cient, optimal

operation of the hydroelectric plant

Cost e�ective

Maintenance-free measurement

User friendly

Simple installation on existing

structures

7

Level and pressure measurement in the expansion tank for heat transfer fluid (HTF)

The solar heat captured in the mirror system of a thermal solar plant is trans-

ported via a heat transfer fluid (HTF) to the steam generator at the central

turbine. The HTF normally has a temperature between 300 °C and 400 °C.

There are di¤erent containers for the fluid across the plant and the varying

temperatures cause volume changes to the HTF that need to be accurately

measured to operate the plant safely and profitably.

VEGAPULS 62

Non-contact level measurement with radar in the expansion

vessel for heat transfer fluid

▪ Reliable function, even at high temperatures

▪ High-resistance materials guarantee long service life

▪ Wear-free operation ensured through non-contact

measuring method

VEGABAR 81

Pressure measurement in the thermal solar plant pipeline

systems

▪ Highly resistant to overloading due to pressure surges

▪ Long service life thanks to seal-free measuring cells

▪ Wear and maintenance-free due to high-resistance

diaphragm materials

Reliable

Highly overload-resistant measuring

systems

Cost e�ective

Accurate level measurement for optimal

utilization of the container volumes

User friendly

Easy instrument selection: one sensor

version fits all tank sizes

Expansion tank in a thermal solar plant

8

Oil tank point level detection in the rotor gearbox

In wind turbines, e±ciency has top priority: the higher the availability of a

turbine, the higher the profitability and the faster the investment pays o¤. Wind

power is transferred from the turbine to the generator via a rotor gearbox. Full

lubrication of all moving parts ensures a long service life and high availability

of the wind turbine, thus making it essential for the oil level in the rotor gearbox

to be constantly and reliably monitored.

VEGASWING 51

Dry run protection with vibrating level switch in the oil tank

of a rotor gearbox

▪ Media-independent switching point guarantees high

dependability

▪ Fast setup and commissioning, because adjustment

requires no medium

▪ Compact instrument dimensions allow easy installation

Reliable

Media-independent switching point

Cost e�ective

Protection against wear through

continuous oil lubrication

User friendly

Compact dimensions allow easy

integration into any system

Gearbox oil tank in a wind turbine

9

Level measurement and point level detection in a corrugated metal silo

The finished pellets are stored ready for delivery in corrugated metal silos up

to and over 30 m high. Larger storage volumes allow the supplier to better

respond to the increased demand during the heating season and utilize the

production equipment continuously throughout the year. For optimal planning

of material logistics, a reliable measurement of silo contents is a must.

VEGAPULS 69

Non-contact level measurement with radar in the pellet silo

▪ Wear-free thanks to non-contact measurement

▪ Easy mounting and setup due to top installation

▪ Good focusing of the radar beam enables sure

measurement even during filling

VEGAVIB 63

Point level detection with vibrating level switch in the storage silo

▪ Reliable level signal under all operating conditions

▪ Wear and maintenance-free

▪ Easy to install and adjustment-free

Wood pellet storage silo

Reliable

Highly dependable and accurate level

measurement, even during filling

Cost e�ective

By optimising silo volumes, it results in

better utilization of production capacity

User friendly

Simple mounting, installation from top

10

Level measurement in energy production from waste

Biogas plants convert a mixture of organic waste and renewable raw materials

into valuable energy through fermentation using a largely CO2 neutral process.

Optimal consumption of the resources and maintenance-free operation require

the use of highly reliable measurement technology. In all production steps –

from the delivery of raw materials and waste to the removal of residues – the

levels must be closely and accurately monitored.

VEGAPULS WL 61

Non-contact level measurement with radar in the slurry tank

of a biogas plant

▪ Radar measurement is completely independent of ambient

conditions

▪ Non-contact measurement allows maintenance-free

operation

▪ Simple mounting reduces installation costs

VEGAWELL 52

Hydrostatic level measurement with submersible pressure

transmitter

▪ High durability ensures long service life

▪ Hydrostatic measurement independent of surface foam

▪ Simple setup and commissioning reduces costs

Compact slurry tanks in biogas plants

Reliable

Trouble-free operation of the fermenter

with technology

Cost e�ective

Long service life ensured through

non-contact measuring method

User friendly

Easy installation and retrofit, through

external vessel mounting

11

Point level and pressure measurement in energy production in slurry tanks

Semi-liquid manure, or slurry, in biogas plants is often stored in closed,

large-volume slurry tanks. Through fermentation, a valuable energy carrier

is extracted from the mixture of organic waste and renewable raw materials.

Level and pressure are monitored in the tank, as well as in the delivery and

removal systems handling the raw materials and waste.

VEGACAP 64

Point level detection with capacitive level switch for full

and empty alarm in the slurry tank

▪ Non-sensitive to product buildup, even under conditions

of extreme fouling

▪ Robust, maintenance-free sensor design

▪ Adjustment-free setup and commissioning minimizes costs

VEGABAR 82

High-precision pressure measurement in the fermenter

▪ Di¤erent measuring cells allow targeted application solutions

▪ High chemical and mechanical resistance thanks to ceramic

measuring cell

▪ Wide array of process fittings ensures easy integration

into existing systems

Slurry tanks in biogas plants

ReliableReliable operation of the fermenter through overflow protection

Cost e�ectiveUniversally applicable and modular sen-sors throughout the biogas plant, thus very cost-e¤ective spare parts stocking

User friendlyMaintenance-free operation with technologies not a¤ected by buildup

12

Level measurement and point level detection in the grain silo

Ethanol is an additive used in gasoline. Through the use of renewable resources,

the CO2 emission of fuels is significantly improved and the consumption of crude

oil reduced. In modern ethanol plants, raw materials such as grain, sugar cane

or sugar beet are processed into alcohol and ethanol. The resulting by-products

and residues are also completely utilized. The di¤erent types of grain used for

ethanol production are stored in silos more than 20 m high. Reliable silo level

measurement is essential to ensure continuous production supply is maintained.

VEGAPULS 69

Level measurement with radar in the grain silo

▪ Reliable measurement, even with changing media

▪ Easy mounting and setup thanks to installation

from above

▪ Trustworthy measurement data even during filling

VEGAVIB 62

Point level detection with vibrating level switch

▪ Wear and maintenance-free

▪ Easy to install and adjustment-free

▪ Reliable point level detection, even with changing media

Raw material silo in the ethanol plant

ReliableReliable level measurement for trouble-free operation of the raw material stocks

Cost e�ectiveComplete utilising of the silo without mechanical overload

User friendlyEasy installation in the container roof with exact alignment for optimum measurement accuracy

13

Level, switching and pressure measurement in the conversion process for alcohol production

The heart of the ethanol plant is the fermentation process. This is where the

sugars in the mash are converted into alcohol, which, in the subsequent

distillation process, is then concentrated to a strength of 99.9 %. The CO2

gas given o¤ by the fermentation is captured and used for carbonation in the

beverage industry. To keep the fermenter vessel operating in its optimal range,

reliable monitoring of the process parameters including the vessel level and

overall pressure is required.

VEGABAR 82

Measurement of the level and gauge pressure during mash

fermentation with electronic di¤erential pressure

▪ High abrasion resistance thanks to ceramic materials

▪ Di¤erent measuring cells enable application oriented

selection

▪ Easy cleaning thanks to front-flush measuring cells

VEGACAP 64

Capacitive point level detection of the mash in the

fermentation process

▪ Reliable foam detection, regardless of consistency

▪ Una¤ected by buildup, even with product deposits

and thick foam

▪ Adjustment-free setup and commissioning minimizes costs

ReliableAccurate readings under all process conditions in the fermenter

Cost e�ectiveLevel and pressure measurement using electronic di¤erential pressure provides all relevant measurement data

User friendlySimple mounting and setup

Fermentation in the ethanol plant

14

VEGAFLEX 81

Level measurement with guided radar in the bioethanol

storage tanks

▪ High accuracy, una¤ected by medium and vapours

▪ Simple mounting from above greatly facilitates

retrofitting

▪ High reliability through device accreditation to SIL2

VEGASWING 63

Level detection with vibrating level switch as overfill protection

in the bioethanol storage tanks

▪ Adjustment-free setup and maintenance-free operation

▪ Simple function test via keystroke

▪ Reliable point level measurement in compliance with

SIL2 and WHG

Level measurement and point level detection in the ethanol storage tank

After going through all process steps, the bioethanol is stored in a tank ready

for delivery to the consumer. Accurate measurement of the tank contents is

an important prerequisite for fiscal inventory, reliable logistics planning and

ensures a su±cient supply for customers. Since the tanks can often not be

emptied after an initial filling, maintenance-free operation and setup without

product are crucial considerations for the measurement technology.

Storage tank in the ethanol plant

ReliableReliable level measurement ensures safe operation of the ethanol depot

Cost e�ectiveHigh-precision measurement allows optimal utilization of the tank volume

User friendlyInstallation from top, o¤ers easy mounting and simple adjustment, even when tank is full

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VEGA Grieshaber KGAm Hohenstein 11377761 SchiltachGermany

Phone +49 7836 50-0Fax +49 7836 50-201E-mail [email protected]

level and pressure instrumentation for renewable energies

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